1	Perfe¢t Pack Frequently Asked Questions
2	How high can you stack packed rolls? The 24s can be stacked 5 high, with a total of 8,000 pounds. The 30s can be stacked 4 high, with a total of 9,000 pounds. The 34s can be stacked 4 high, with a total of 10,000 pounds.
3	How do you move the roll? Through the core. The preferred method of moving the Perfe¢t Pack shipping system, loaded with a roll of product, is by using the core as the method of support and transportation, vs. a pallet. This involves the placement of a fork lift fork inside the core and lifting the package and transporting the package to its staging area. The preferred fork size is 1.75 inches thick, by 4 inches wide, by 60 inches long. Other sizes work, however must be compatible with the core opening, as to not damage the core edge or plug.
4	What is the recommended banding method? The first band should be placed through the roll core and passed under the Perfect Pack end boards. This band brings the package together and allows for constant tension between all three recommended bands. This band should be secured at the end opposite the roll carrier, assist or fork truck, if suspended by one side. The next two bands can be located either in the horizontal position passing through the banding guides on the side, or over the top in the banding notches in the 2x4 bracing area or notches provided to the sides.
5	How many can you move at once? Up to four, if placed in a “Four Pack” configuration. This is accomplished by placing 2x6 rough cut lumber in the upper brace area of the bottom row. The packages are then cross banded through the cores to bind them together. Two rolls can be moved at one time (side by side), if the fork centers can match the roll centers. Also, the fork truck rating as to loads and their relative position must be consulted before safe transportation should be attempted. It should be noted that one roll should not be lifted on top of another, using the bottom roll as the “pallet”.
6	Is there a procedure in which the Perfect Pack end flanges can be located without lifting? Yes, the parts can be located on the floor by the material handler for prestaging of the packing material. Then the roll is then positioned near the floor and the part is then moved in place on the floor, by sliding, and placed over the core or core extention.
7	Can I pack flush core rolls? Yes. The challenge is to produce a core extension, with scrap core and a plug of your choice. This can be ordered from your plug or core supplier in the proper material (paper or plastic) and with the core attached or not. Banding through the core helps prevent the core extension from being pulled out during off loading.
8	What is the preferred banding material? Polyester, due to its non stretch charteristics.
9	How do our customers benefit? First by safety. The less number of parts, the lower change of injury. No Pallets to bend over and move. Regardless of rules and training, these injuries still occur. Less fork lift traffic in the packing or winding areas. Less personnel needed due to quicker and easier packing.
10	Can this unit be stretch wrapped? These packaging units can be converiorized and stretched with normal stretch machines. They can also be bagged and shrink wrapped as well, if the investment warrants. Or the rolls can be bagged and no covering used at all!
11	Can we adapt our core to one of your standard sizes? Yes, we can design an adaptor ring of MDF board that will adapt your core to one of our larger core support areas on the Perfect Pack.
12	Do they have to be stacked perfectly? No. We designed the PP system to be miss-stacked as much as 4 inches inches. This means that equal length packages can be miss-aligned as much as 4 inches before an unsafe condition exist. So the safe stacking target is much larger than most conventional pallet systems of 1 inch end board or less and a stringer on the pallet.
13	Can you put this on a pallet? Yes. There are three places that the Perfect Pack end flange can be secured with a T Block. The T blocks are needed to prevent the plastic from sliding on the pallet. One on each end will secure rolls up to 1,100 pounds, two to 2,200 and three for to 3,300.
14	Can you ship these units two high? Yes. Shipping test indicate that when the loads are properly locked, then two high shipping is not a problem. The interlocks provide excellent stability of the rolls and prevent from shifting of the load. If extremely bad road conditions occur, then 2x6s can be placed in the bottom row to prevent movement.
15	How long do they last? It has been our experience that HDPE pallets last 7 years and roughly 50-100 trips. The Perfect Pack system is made of engineering plastic, ABS, and there fore should last this long or longer. Most damage occurs from ‘marshalling’ the roll on the floor and the fork breaks out ribs, decreasing the load bearing ability of the part.
16	What has been the fallout to date? There are more than 12,000 in service and less than 50 have broken. This is less than one percent per year.
17	How do we get used to this packaging concept? The best use of the Perfect Pack to train operators, is to use the packaging in house, split downs and scrap storage. Then progress to inter company transfers.
18	Does this work for international shipments? Both the 24 inch and the 30 inch pack out a container very well and reduce the amount of packaging by 50% and the weight usually by 15%. More film and less material to return. Safer packing and unpacking of the container.
19	How much floor space do we need? Up to 25% better floor utilization than wood in racks or free standing wood. Less space due to no pallet storage, inside or out. Less space due to no pallet designed shipping and return configuration.